Instruction/ maintenance manual of the product Pump Flowserve
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U S E R I N S T R U C T I O N S Durco Mark 3 s ealed metallic pump s Mark 3 S tandard, In-Line , Lo-Flo, Recessed Impeller , Unitized Self-Priming and Sealmat ic pump s PCN=71569102 08-06 (E) (incorpo.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 2 of 68 f l o w s e r v e . c o m CONTENTS Page CONTE NTS ......... ........ ...... ........ ......... ........ ........ .... 2 1 INTRO DUCTION AND S AFETY ... ... .... ... .... ... .. .... 3 1.1 Ge nera l .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 3 of 68 f l o w s e r v e . c o m 1 INTRODUCTION AND SAFETY 1.1 General These instructi ons must alw ays be kept close to the prod uct’ s o perating l oc ation or directly w ith the product.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 4 of 68 f l o w s e r v e . c o m 1.6 Safety 1.6.1 Summary of safety mark ings Th e se U ser In st ruc tion s c ont ai n s pec if ic safe ty m ar king s w her e non -o b se rva nce o f an in s tr uct io n w oul d ca use haz ar ds .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 5 of 68 f l o w s e r v e . c o m HAZ ARDOUS LIQU IDS W hen the pump is handling hazardous liquids care must be taken to av oid exposure to the liqu id by appropriate pu mp placement, limit ing personnel access and by operator training.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 6 of 68 f l o w s e r v e . c o m 1.6.4.2 Mar king An example of A TEX equ ipment marking is shown below .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 7 of 68 f l o w s e r v e . c o m In addi tion, it is essential to mak e sure that seal chambers, auxiliary shaft seal systems and an y heating and cooling systems are properly filled.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 8 of 68 f l o w s e r v e . c o m 1.8 Noise level Attention must be given to the ex posure of personnel to the noise, and local legislation will define when guidance t o personnel on noise limit ation is required, and when nois e exposure reduct ion is mandator y.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 9 of 68 f l o w s e r v e . c o m 2 TRANSPORT AND STORAGE 2.1 Consignment receipt an d unpacking Immediately af ter receipt of the equipment it must be checked against the delivery/shi pping documents fo r its completeness and that there has been no damage in trans portation.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 10 of 68 f l o w s e r v e . c o m Figure 2-2 2.3 .2 L ift ing pump , mo t o r and base plate ass embly 2.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 11 of 68 f l o w s e r v e . c o m Af ter u npa cki n g, p rot ecti on w il l be the re spon sib il ity o f th e u ser . A ddi tio n o f oi l t o the be ari ng ho usin g w ill re m ove th e i nhi bit or.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 12 of 68 f l o w s e r v e . c o m 3.3 Design of major p arts 3.3.1 Pump cas ing R em ov al o f th e c asi ng is no t r equ i red whe n p e rfor ming m ain ten an ce o f th e ro tati ng el eme nt.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 13 of 68 f l o w s e r v e . c o m Figure 3-2: Alloy cross-reference c hart Flo w se rve ma ter i al co de Designation Durco legacy codes ACI designation Equivale nt wrought designation ASTM specifications Material Group No.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 14 of 68 f l o w s e r v e . c o m Figure 3-3: Class 150 fla n ges Material Group No. 1.0 1.1 2.1 2. 2 2.8 3.2 3.4 3. 5 3.7 3.8 3.17 Ti Cr Temp ºC ( ºF) bar (psi) -73 (-100) – – 19.0 (275) 19.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 15 of 68 f l o w s e r v e . c o m Figure 3-4B: Group 2 - 13 in. Lo-Flo pumps with Class 300 flanges Material Group No. 1.0 1.1 2.1 2.2 2.8 3.2 3.4 3.5 3.7 3.8 3.17 Ti Temp º C ( º F) bar (psi) -73 (-100) – – 31.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 16 of 68 f l o w s e r v e . c o m Figure 3-5a: Suction pressure l imits 1 750 r/mi n 0 2.5 5 7.5 10 12 .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 17 of 68 f l o w s e r v e . c o m Figure 3-6: Suction pressure refer ence numbers Pump size 1 750 3 50 0 1K 1.5x 1-6 7 10 1K 3 x1.5-6 10 15 1K 3 x2-6 10 12 1K 2 x1. 5V-6 PT 18 1K 1.5x 1-8 1K 1.5x 1.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 18 of 68 f l o w s e r v e . c o m 4 INSTALLATION Zirconium 702 or high chrome ir on comp onents If any of the component s of the pump have been m.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 19 of 68 f l o w s e r v e . c o m Some users may desire an even flatter surface, which can facilitate installation and al ignment. Flowserve w ill supply flatter bas eplates upon request at extra cost.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 20 of 68 f l o w s e r v e . c o m k) It should be noted that the connecting pipelines must be individually support ed, and that the spring mounte d baseplate i s not intended to support t otal static pipe loads.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 21 of 68 f l o w s e r v e . c o m f) After leveling the baseplate, t ighten the anchor bolts. If shims were used, mak e sure that t he baseplate was shimmed near each anchor b olt before t ightening.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 22 of 68 f l o w s e r v e . c o m Mark 3 design (old) If an adj us tmen t is nec e ss ary , th e adj ust er nu t [6 576 ] i s u sed to m ove th e f oo tpi ece u p o r do w n. g) The spacer co upling gap is verified.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 23 of 68 f l o w s e r v e . c o m Fi gur e 4 -9 i llu str a te s th e id ea l pip ing co nf igu rat io n w it h a mi nim u m of 1 0 pip e di ame ters be tw een t h e sou rce and th e p u mp su cti on .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 24 of 68 f l o w s e r v e . c o m f) C om pa re th e “ adj ust ed Fi gu re 4 -1 6 l oa ds” t o t he va l ues s how n in fi gur e 4 -15 . The lo w er of the se tw o v alu es sh oul d b e u sed as t h e adj ust ed fi gur e 4 - 15 va l ue s.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 25 of 68 f l o w s e r v e . c o m Figure 4-12: Baseplate corr ection factors Base typ e Grouted Bolted Stilt mounted Type A 1.0 0.7 0.65 Type B - Polybase 1.0 n/a 0.95 Type C n/a 1.0 1.0 Type D 1.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 26 of 68 f l o w s e r v e . c o m Figure 4-15: Maximum individual loading Suction flange Dischar ge flange Forces N (lbf) Moments Nm (lbf•ft) Forces N (lbf) Moments Nm (lbf• ft) Pump size Fxs Fys Fzs Mxs M y s Mz s F xd Fyd Fzd Mx d Myd Mzd 1K 1.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 27 of 68 f l o w s e r v e . c o m Figure 4-16: Maximum combined l oading Suction flange Discharge flan ge Forces N (lbf) Moments Nm (lbf• ft) Forces N (lbf) Mom ents Nm (lbf• ft) Pump size Fxs Fys Fzs Mxs M y s Mz s Fxd Fyd Fzd Mxd My d Mz d 1K 1.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 28 of 68 f l o w s e r v e . c o m Figure 4-17: Maximum Y-axis loading for shaft deflecti on Suction flange Discharge flange Forces N (lbf) Moment.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 29 of 68 f l o w s e r v e . c o m Figure 4-19 4.6. 4.2c Pump stand limi t ations In cases where the pump is rigidly mounted by the pump stand, both the c asing limitations and the pump st and lim itations must be satisf ied.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 30 of 68 f l o w s e r v e . c o m Figure 4-22: Allowable stand l oads F T MA X in N (lbf) F N MAX in N (lbf) Combination lo ading in N (lbf) GP1 pu mps 8 020 (1 800) 108 531 (24 400) F N + (13.556) F T F N + (13.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 31 of 68 f l o w s e r v e . c o m 4.6.6.4 P iping connection - bearing h ousing cooling system Make connect ions as shown bel ow. Liquid at less than 32 ° C (90 ° F) should be supplied at a regulated flow rate of at least 0.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 32 of 68 f l o w s e r v e . c o m The mot or must be wired up in accordance wit h the motor manufac turer’ s instruct ions (normally supplied within the t erminal box) including any temperat ure, earth leakage, current and other protect ive devices as appropriate.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 33 of 68 f l o w s e r v e . c o m If t here is any possibility of t he system allowing t he pump to r un against a closed valve or below minimum cont inuous saf e flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsaf e level.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 34 of 68 f l o w s e r v e . c o m In ma ny pu mpi n g app li ca ti ons lu b ric a ti ng oi l b e co me s co nta mi n at e d b e fo re it lo se s i ts lu b rica tin g q ua lit ie s o r br eak s do wn .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 35 of 68 f l o w s e r v e . c o m 5.2.2 Gr ease 5.2.2.1 Regre asable Single shielded r egreasable bear ings W hen the grease lubrication opt ion is specified, single shielded bearings, grease fittings and v ent pipe plugs are installed inboard and out board.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 36 of 68 f l o w s e r v e . c o m 5.2.3 Oil mist The inlet port for all horizontal pumps is the plugg ed ½ in. NPT loc ated at the top of t he bearing housing. A vent fitt ing has been supplied on t he bearing carrier as well as a plugged ¼ in.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 37 of 68 f l o w s e r v e . c o m Only one side of the guard needs to be removed. To reassemble s imply reverse the above procedure. Figure 5-15 The coupling guar d shown in f igure 5-15 conf orms to the USA stand ard ASME B15.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 38 of 68 f l o w s e r v e . c o m The Mark 3 Unitized self-priming c entrifugal pumps have a s lig htly diff erent requirement regarding priming. The initial priming liquid must be added t o the pump c asing until the liq uid has reached the bottom o f the suct ion nozzle.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 39 of 68 f l o w s e r v e . c o m 5.9 Stopping and shutdown 5.9.1 Shu tdown co nsiderations W hen the pump is being shutdown, the procedure should be the reverse of the start-up procedure. First, slowl y close t he discharge v alve, shut down th e driver, and then close the suct ion valve.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 40 of 68 f l o w s e r v e . c o m If platfor ms, stairs and guard rai ls are required for maintenance, they must be placed for easy access t o areas where maint enance and inspecti on are to be carried out .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 41 of 68 f l o w s e r v e . c o m Prior to resizing impellers in high chrome iron and nic kel, please c onsult your local Flowserve s ales representativ e. 6.2.1 Or dering of spare parts Flowserve k eeps records of all pumps that have b een supplied.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 42 of 68 f l o w s e r v e . c o m 6.6 Setting impeller clearance and impeller replacement A new impeller gasket [45 90.2] must be installed whenever the impeller has been remov ed from t he shaft.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 43 of 68 f l o w s e r v e . c o m Lastly, unif ormly tighten t he set sc rews [6570.3] in incremental steps up t o the final torque value to l oc k th e bea ri ng ca rrie r i n p l a ce . Figure 6.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 44 of 68 f l o w s e r v e . c o m Th e ab ov e p roc ed ur e i s fa ir ly s trai ght fo rwa rd w hen do ing t h e fi nal se tti n g o f t h e i m pel ler .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 45 of 68 f l o w s e r v e . c o m 6.7.2 Pump di sassembly k) Remove t he coupling hub f rom the pump shaft [2100].
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 46 of 68 f l o w s e r v e . c o m M ar k 3 des ign On Gr oup 1 a n d 2 p ump s the be arin g c arri er is tu rne d b y u sing a stra p w ren ch , w ith the st ra p lo ca te d a roun d th e o utsi de dia met er o f th e ca rri er fa ce.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 47 of 68 f l o w s e r v e . c o m Figure 6-18 6.8 Examination of parts 6.8.1 Cleaning/inspection All parts s hould now be thor oughly cleaned and inspected. New bearings, O-r ings, gaskets, and lip seals should be used.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 48 of 68 f l o w s e r v e . c o m Figure 6-19 Topic ASME B73.1M standard mm (in.) Suggested by major seal vendors mm (in.) Suggested and/or provi ded by Flowserv e mm (in.) Shaft Diameter tol erance, under bearin gs n/s 0.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 49 of 68 f l o w s e r v e . c o m Deflecti on Shaft end play The maximum amo unt of axial shaft mov ement, or endplay, on a Durco pump should be 0.03 mm (0.001 in. ) and is measured as shown below.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 50 of 68 f l o w s e r v e . c o m Many companies today are using laser alignment which is a more sophisticated and accurate technique. W ith this met ho d a laser and sensor measure misalign ment.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 51 of 68 f l o w s e r v e . c o m a) In st al l th e i nb oa rd b e a rin g [3 01 1 ] on t he s h a ft [2 10 0] . Mark 3A and ANSI 3A design The inboard bearing must be positioned against the shoulder as shown in figure 6-22.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 52 of 68 f l o w s e r v e . c o m c) Insta ll the outboard bear ing. Double row bearings Install th e outboard bearing [ 3013] firmly against the shoulder as shown in figure 6-22.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 53 of 68 f l o w s e r v e . c o m N e ve r c om pre ss th e sn ap r ing un les s i t i s po sit io ned ar o und th e s haft an d b etwe en th e b e a rin g s.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 54 of 68 f l o w s e r v e . c o m f) Lo ca te t he ro tar y s eal uni t o nt o t he sh aft ( or sle e ve ) ac co rdi ng to th e se t d im ensi o n p ro vide d b y the se a l m anu fa ct ure . T igh ten se t sc rew s on th e se al t o lo ck th e r ota tin g u ni t to th e s h a ft /s l ee ve.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 55 of 68 f l o w s e r v e . c o m i) Reinstall t he repeller cover, r epeller, rear cover, and impeller as instructed in section 6. 9.3. j) The Ch ec kma tic gl and mu st n ow be mov ed fo rw ard to w a rd t he im pel le r, pu shi ng th e f or w ard l i p a he ad of it .
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 56 of 68 f l o w s e r v e . c o m 6.9.4 Close coupled final assembl y a) Install th e motor adapter [3160] onto the bearing housing using three screws [ 6570.15]. b) Install unit int o casing as described in section 6.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 57 of 68 f l o w s e r v e . c o m 7 FAULTS; CAUSES A ND REMEDIES The following is a guide to troubles hooting problems with F lowserve Mark 3 pumps. Common prob lems are analyzed and solutions offered.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 58 of 68 f l o w s e r v e . c o m Pump not reaching design flo w rate Pump not reaching design head (TDH) No discharge or f low with pump runni n.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 59 of 68 f l o w s e r v e . c o m 8 PARTS LIST AND DRAWINGS 8.1 Standard Mark 3 pump, Group 1 Optional du p lex arrangement Item Description 32 00 B earing h ousing 4610.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 60 of 68 f l o w s e r v e . c o m 8.2 Standard Mark 3 pump, Group 2 and Group 3 Group 2 Opti onal duplex bearing ar rangement Group 3 Standar d bearing clamp arrangement Item Description 32 00 B earing h ousing 4610.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 61 of 68 f l o w s e r v e . c o m 8.3 Mark 3 Sealmatic pump, Group 2 8.4 Mark 3 Lo-Flo, Group 2 Item Description 297 Seat 298 Lipseal 1100 Casing 1220 Cover 1220.1 Cover - repeller 2200 Impell er 2200.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 62 of 68 f l o w s e r v e . c o m 8.5 Mark 3 Unitized Self Priming pump, Group 2 8.6 Mark 3 Recessed Impeller pump, Group 2 Item De scription 1100 Casing 2200 Impeller 4590.1 G asket – c over 4590.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 63 of 68 f l o w s e r v e . c o m 8.7 Mark 3 In-Line pump, Group 1 Item Description 4120 Gland 6570.3 S c rew - bearing carrier set 1100 Casing 4130 Packing - optio nal 6570.12 S crew - clamp 1220 Cover 4134 Seal cage – packing op tional, 6 570.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 64 of 68 f l o w s e r v e . c o m 8.8 Mark 3 In-Line pump, Group 2 Item Description 3712 B ear ing l ocknut 6569.3 P lug – sight gage 1100 Casing 4120 G land 6 570.1 Screw - casing 1220 Cover 4130 Packing - optional 6570.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 65 of 68 f l o w s e r v e . c o m 8.9 Mark 3 C-Face Adapter, Group 1 and Group 2 Item Description 6570.17 Screw – foot set screw 3134 Support foot 6572.4 St ud - motor 3160 Motor pedestal – C-Face 6575 Ja cksc rew 3200 Bearing housing 65 80.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 66 of 68 f l o w s e r v e . c o m 9 CERTIFICATION Certificat es, determined fr o m the cont ract requirements are provided with these instruct ions where applicable. Examples are certificates for CE marking and A TEX marking etc.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Page 67 of 68 f l o w s e r v e . c o m Notes:.
MARK 3 USER INSTRUCTIONS ENGLISH 715 69102 08-06 Your Fl owserve factory contacts: Flowser ve Pump Division 3900 Co ok Boulevard Chesapeake, VA 23323-1626 USA Telephone +1 757 485 8000 Fax +1 757 485 .
An important point after buying a device Flowserve Pump (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Flowserve Pump yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Flowserve Pump - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Flowserve Pump you will learn all the available features of the product, as well as information on its operation. The information that you get Flowserve Pump will certainly help you make a decision on the purchase.
If you already are a holder of Flowserve Pump, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Flowserve Pump.
However, one of the most important roles played by the user manual is to help in solving problems with Flowserve Pump. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Flowserve Pump along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
